Composite textile fabrics

ABSTRACT

A composite textile fabric that includes a first (face) fabric layer, and a second (back) fabric layer that is formed concurrently with the first fabric layer in a plaited construction. The second fabric includes a plurality of anchored regions at which the second fabric layer is anchored to, and in intimate contact with, the first fabric layer. The second fabric layer also includes a plurality of floating regions, overlying and unattached to the first fabric layer, interspersed between the anchored regions.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/957,290, filed on Apr. 19, 2018, which was a divisional applicationof U.S. patent application Ser. No. 13/009,324, filed on Jan. 19, 2011,which claims benefit from U.S. Provisional Patent Application61/296,103, filed Jan. 19, 2010, all of which are herein incorporated byreference in their entirety.

TECHNICAL FIELD

This invention relates to composite textile fabrics and related fabricarticles and methods.

BACKGROUND

Composite textile fabrics are achieved by joining together differentmaterials in a fabric body for the purpose of attaining desirableproperties that cannot be attained by the individual materials alone.

One known composite textile fabric, which is utilized in fabricgarments, features a bi-component plaited knit construction that usesdifferent yarns on either side of the fabric. This creates two differentfabric layers: a first fabric layer that is worn towards the skin and isconstructed to move moisture away from the skin, and a second, oppositefabric layer that is optimized to dry quickly. In high exertion physicalactivity, however, the first fabric layer can have a tendency to stickto the skin (clinging), which may reduce air flow and sweat evaporation.This can cause a chilling effect after the physical activity hasstopped.

SUMMARY

In general, this invention relates to composite textile fabrics andrelated fabric articles (e.g., garments) and methods.

One aspect of the invention provides a composite textile fabric thatincludes a first (face) fabric layer, and a second (back) fabric layerthat is formed concurrently with the first fabric layer in a plaitedconstruction. The second fabric layer includes a plurality of anchoredregions at which the second fabric layer is anchored to, and in intimatecontact with, the first fabric layer. The second fabric layer alsoincludes a plurality of floating regions, overlying and unattached tothe first fabric layer, interspersed between the anchored regions.

Another aspect of the invention features a method of forming a compositefabric article. The method includes combining high shrinkage yarn andlow shrinkage or no shrinkage yarn to form a fabric body having aplaited construction. The high shrinkage yarn forms a first fabric layerof the fabric body and the low shrinkage or no shrinkage yarn forms asecond fabric layer of the fabric body. The second fabric layer includesa plurality of anchored regions at which the second fabric layer isanchored to, and in intimate contact with, the first fabric layer, and aplurality of floating regions, overlying and unattached to the firstfabric layer, interspersed between the anchored regions. The method alsoincludes exposing the fabric body to heating sufficient to cause thefirst fabric layer to shrink relative to the second fabric layer suchthat the floating regions separate (buckle outwardly) from the firstfabric layer.

In another aspect, the invention provides a fabric garment that includes(e.g., is formed of) a composite textile fabric including a first (face)fabric layer and a second (back) fabric layer formed concurrently withthe first fabric layer in a plaited construction. The second fabriclayer includes a plurality of anchored regions at which the secondfabric layer is anchored to, and in intimate contact with, the firstfabric layer, and a plurality of floating regions, overlying andunattached to the first fabric layer, interspersed between the anchoredregions. The second fabric layer defines an inner surface of the fabricgarment. The plurality of floating regions together with the pluralityof anchored regions defining air gaps between a wearer's skin and thefirst fabric layer, thereby to facilitate ventilation and reduce contactpoints with the wearer's skin, or to provide thermal insulation such aswhen the fabric garment is utilized as a first layer in a multilayerfabric system.

Embodiments may include one or more of the following features.

In some embodiments, the fabric has a plaited single jersey constructionor a double knit construction.

In certain embodiments, the first fabric layer includes a high shrinkageyarn, and the second fabric layer includes a low shrinkage or noshrinkage yarn.

The high shrinkage yarn responds to application of heat (e.g., dry heatand/or wet heat, such as hot water or steam, e.g., during dyeing).

In some embodiments, the high shrinkage yarn includes an elastomericmaterial (e.g., Lycra, spandex).

In certain embodiments, the high shrinkage yarn is a textured yarn or aspun yarn.

In some embodiments, the low shrinkage or no shrinkage yarn is atextured filament yarn, or flat filament yarn, or a spun yarn.

The high shrinkage yarn is finer (i.e., has finer denier) than the lowshrinkage or no shrinkage yarn.

In some cases, the low shrinkage or no shrinkage yarn is finer than thehigh shrinkage yarn.

In some embodiments, the high shrinkage yarn and the low shrinkage or noshrinkage yarn have the same fineness.

In some cases, the high shrinkage yarn is in a size range of about 50denier to about 150 denier, and wherein the low shrinkage or noshrinkage yarn is in a size range of about 50 denier to about 300denier.

In certain embodiments, yarn forming the first fabric layer is finerthan yarn forming the second fabric layer.

In some cases, yarn forming the second fabric layer is finer than yarnforming the first fabric layer.

In certain embodiments, yarn forming the second fabric layer and yarnforming the first fabric layer have substantially the same fineness.

In some cases, yarn forming the first fabric layer is in a size range ofabout 50 denier to about 150 denier, and yarn forming the second fabriclayer is in a size range of about 50 denier to about 300 denier.

Methods can include exposing the fabric body to dry heat and/or to wetheat, such as hot water or steam, e.g., during dyeing.

Methods can also include exposing the fabric body to heating for about0.5 minutes to about 60 minutes at about 200° F. to about 450° F.

In some embodiments, the plurality of anchored regions and the pluralityof floating regions are arranged in one or more discrete regions of thesecond fabric layer, and the second fabric layer also includes one ormore other discrete regions having a plain plaited construction.

In certain embodiments, the plurality of floating regions are arrangedin a pattern corresponding to one or more discrete regions of thewearer's body.

In some embodiments, the plain plaited construction has a jacquardpattern.

In certain embodiments, the plurality of floating regions includefloating regions of contrasting size.

In some embodiments, the plurality of floating regions are arranged inpatterns of contrasting density.

In certain embodiments, the plurality of floating regions can bearranged to form contrasting patterns.

In some embodiments, the plurality of floating regions can havediffering sizes.

In certain embodiments, the first fabric layer includes elastomeric yarn(e.g., spandex yarn). The second fabric layer may include a low stretchor no stretch yarn.

In some embodiments, the first fabric layer and/or the second fabriclayer include flame retardant yarns and/or fibers.

Other aspects, features, and advantages are in the description,drawings, and claims.

DESCRIPTION OF DRAWINGS

FIG. 1 is a plan view of a composite textile fabric.

FIG. 2A is a front perspective view of a fabric garment formed ofcomposite textile fabric.

FIG. 2B is a cross-sectional view of the fabric garment of FIG. 2B,taken along line 2B-2B.

FIG. 3 is a knitting notation for forming a fabric body of a compositetextile fabric.

FIG. 4 illustrates a fabric body of a composite textile fabric beforeand after exposure to heat.

FIGS. 5A and 5B are front plan and rear plan views, respectively, of afabric garment formed of composite textile fabric having discreteregions with a bubble configuration and other discrete regions with aplain plated construction.

FIG. 6 is a front plan view of a fabric garment formed of compositetextile fabric having regions of contrasting bubble density.

FIG. 7 is a front plan view of a fabric garment formed of compositetextile fabric having regions of contrasting bubble size.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

Referring to FIG. 1 , a composite textile fabric 10 includes a firstfabric layer 12 and a second fabric layer 14 that are intimatelyconnected together. The second fabric layer 14 includes a plurality ofanchored regions 16 at which the second fabric layer 14 is anchored tothe first fabric layer 12. The second fabric layer 14 also includes aplurality of “bubbles” or floating regions 18, which are interspersedbetween the anchored regions 16. The floating regions 18 overlie and areseparated (buckle outwardly) from the first fabric layer 12.

Referring to FIGS. 2A and 2B, the composite textile fabric 10 can beincorporated in a fabric garment 20 such that the second fabric layer 14forms an inner surface of the fabric garment to be worn towards thewearer's skin S (FIG. 2B). When the second fabric layer 14 is worntowards the wearer's skin S, the plurality of floating regions 18 andthe plurality of anchored regions 16 together define air gaps 19 betweenthe wearer's skin S and the first fabric layer 14. These air gaps 19allow air, flowing transversely to the wearer's skin, to penetrate thetextile fabric 10 to promote evaporation of liquid sweat and reducecontact points with the wearer's skin S.

The fabric garment 20 (FIG. 2A) may also be form part of a multilayersystem for cold weather. In this regard, the fabric garment 20 may, forexample, be worn as a first, inner layer underneath an outer, shelllayer. When incorporated in such a multilayer system, the fabric garment20 provides for thermal insulation by entrapping air.

The first and second fabric layers 12, 14 are formed by knitting twodifferent yarns having significantly different shrinkage performancewhen exposed to dry or wet heat (e.g., steam or high temperature water).The first fabric layer 12 is formed of a face yarn. The face yarn is atextured yarn or a spun yarn having high shrinkage (e.g., about 10-60%shrinkage) after being exposed to dry or wet heat (e.g., for about 0.5minutes to about 60 minutes at about 200° F. to about 450° F.). The faceyarn can include materials selected from natural fibers, regeneratedfibers, synthetic fibers, or blends thereof. A suitable face yarn ispolyester or nylon. The second fabric layer 14 is formed of a back yarnhaving low or no shrinkage (e.g., about 0-30% shrinkage) after beingexposed to dry or wet heat (e.g., for about 0.5 minutes to about 60minutes at about 200° F. to about 450° F.). The back yarn can be atextured filament or flat filament yarn or a spun yarn. The back yarncan include materials selected from natural fibers, regenerated fibers,synthetic fibers, or blends thereof. A suitable back yarn is polyesteror nylon.

The composite textile fabric 10 is formed by combining the face yarn andthe back yarn together by knitting a plaited construction (e.g., plaitedsingle jersey or double knit construction) such that the first fabriclayer 12 and the second fabric layer 14 are distinct and separate butintimated connected together in a unitary fabric body 30 (FIG. 3 ). Theback yarn is anchored to the face yarn by knit and/or tuck and/or weltat certain points (i.e., the anchored regions 16), while other regionsof the back yarn (i.e., the floating regions 18) remain unattached tothe face yarn.

The fabric body 30 can be formed on a double knit jacquard machine, orstep jack double knit machine, or other patterning knitting machine.FIG. 3 is an exemplary knitting notation for a double knit jacquardmachine, which can be used for producing the fabric body 30. The firstfabric layer 12, in double knit, is generally knitted on the cylinderside and the second fabric layer 14 is generally knitted on the dialside. However, in some cases, the face and back yarns can be swapped.

Referring to FIG. 4 , heat is thereafter applied to the fabric body 30,e.g., dry heat and/or wet heat, such as hot water or steam, e.g., duringdyeing. Upon exposure to heat, the face yarn forming the first fabriclayer 12 will shrink and the back yarn forming the second fabric layerwill not shrink or will shrink less than the face yarn. This shrinkagecauses the unattached, floating regions 18 of the back yarn to buckleoutwardly, and separate further away from the first fabric layer 12thereby providing the floating regions 18 with their “bubble” shape.

In some cases, the face yarn includes elastomeric material, such asspandex. The elastomeric material in the face yarn can help to providefor fabric stretch and enhanced user comfort. The elastomeric materialmay be in the form of fibers or filaments co-mingled or plated with highshrinkage fibers or filaments, or core spun in a spun yarn.

The floating regions 18 (“bubbles”) can extend uniformly over the entiresecond fabric layer 14, or, in some cases, the floating regions 18 canhave differing sizes and/or the distribution (pattern density) of thefloating regions 18 can change along the second fabric layer 12. In somecases, the bubble configuration (i.e., the pattern of floating regions18 interspersed between anchored regions 16) can be limited to discreteregions of the composite textile fabric 10, while other regions of thecomposite textile fabric 10 may have a plain plaited construction (i.e.,no fabric bubble regions) and/or a plain plaited construction with somepattern (e.g., a jacquard pattern, but with no fabric bubbles).

FIGS. 5A and 5B illustrate a fabric garment 40 that is formed of acomposite textile fabric. The fabric garment 40 has a front element 42,a rear element 44, and arm elements 46, 48. Each of the elementsconsists of a composite textile fabric, such as described above withreference to FIG. 1 . The elements are joined together, e.g., by stitchat seams 49. Each element defines one or more regions having a bubbleconfiguration 50 (i.e., regions of the composite textile fabric elementsthat include a plurality of floating regions 18 (“bubbles”) interspersedwith a plurality of anchored regions 16) for enhanced air flow andliquid management, and one or more other regions 60 having plain plaitedconstruction (i.e., no fabric bubbles). The floating regions 18 arearranged on an inner surface of the fabric garment 40 and face inwardly,towards the wearer's skin, when the fabric garment 40 is worn. Theregions having bubble configuration 50 are disposed in a patterncorresponding to one or more predetermined regions of a wearer's body(e.g., regions of the wearer's body typically exposed to relatively highlevels of moisture, e.g., liquid sweat) here the chest, arms, and back.

FIG. 6 illustrates another embodiment of a fabric garment 140 that isformed of a composite textile fabric. The fabric garment 140 has a frontelement 142, a rear element 144, and arm elements 146, 148. Each of theelements consists of a composite textile fabric, such as describedabove. The fabric garment 140 includes a region having a first bubbleconfiguration 150, a region having a second bubble configuration 152,and other regions having plain plaited construction 160. The firstbubble configuration 140 includes floating regions 118 a interspersedbetween anchor regions 116 a. Similarly, the second bubble configuration152 includes floating regions 118 b interspersed between anchor regions116 b. The floating regions 118 a, 118 b are arranged on an innersurface 141 of the fabric garment 140 and face towards the wearer's skinwhen then the fabric garment 140 is worn. The first bubble configuration150 has a greater pattern density of floating regions 118 a (i.e., morefloating regions per square inch) than the second bubble configuration152.

FIG. 7 illustrate yet another embodiment of a fabric garment 240 that isformed of a composite textile fabric. The fabric garment 240 has a frontelement 242, a rear element 244, and arm elements 246, 248. Each of theelements consists of a composite textile fabric, such as describedabove. The fabric garment 240 includes a region having a first bubbleconfiguration 250, a region having a second bubble configuration 252,and other regions having plain plaited construction 260. The firstbubble configuration 250 includes floating regions 218 a (bubbles)interspersed between anchor regions 216 a, and the second bubbleconfiguration 252 includes floating regions 218 b (bubbles) interspersedbetween anchor regions 216 b. The floating regions 218 a, 218 b arearranged on an inner surface of the fabric garment 240 and face towardsthe wearer's skin when then the fabric garment 240 is worn. In thisexample, the floating regions 218 a of the first bubble configuration250 are relatively larger than floating regions 218 b of the secondbubble configuration 252.

While certain embodiments have been described above, other embodimentsare possible.

As an example, in some embodiments, the composite textile fabric isconstructed with a denier gradient. More specifically, the face yarn canhave a finer denier than the back yarn. This construction promotes themovement of moisture from the coarser fiber of the back yarn, whichforms the second fabric layer, toward the finer denier fiber of thefirst fabric layer, especially in the anchored regions where there isintimate contact between the first and second fabric layers.

In some embodiments, the denier of the face yarn of the first (outer)fabric layer is in a range of between about 50 denier and 300 denier,while the denier of the yarn of the second (inner) fabric layer is in arange of between 50 denier and 150 denier.

While embodiments have been described in which the first fabric layer isformed of yarn having high shrinkage performance which contributes tothe contrasting shrinkage between the first and second fabric layers, insome embodiments, the first fabric layer may, alternatively oradditionally, include spandex yarn that contributes to or causes thecontrasting shrinkage between the first and second fabric layers. Forexample, as the fabric body is formed (e.g., in a circular knittingprocess) spandex yarn can be incorporated into the fabric body, as aface yarn, in a stretched state. The second fabric layer can be formedof low stretch or no stretch yarn. Once the first and second fabriclayers are intimately joined (e.g., in a plaited construction), thespandex yarn is allowed to retract to its relaxed state causing thefirst fabric layer to contract (shrink) relative the second fabriclayer. This contraction causes the unattached, floating regions of theback yarn to buckle outwardly, and separate further away from the firstfabric layer thereby causing or contributing to the formation of the“bubble” shape, even without exposing it to heat. When spandex isincorporated into the first fabric layer (technical face), thedifferential shrinkage, as a response to heat, between the yarns of thefirst fabric layer and the yarns of the second fabric layer can be quitelow. In some cases, for example, there by may no differential shrinkagein response to heat and the “bubble” effect can be created as a resultof the contraction of the spandex yarn in the first fabric layer.

While an embodiment of a fabric garment is described above in which thegarment is formed of multiple fabric elements that are joined togetherby stitch at seams, in some embodiments, an entire fabric garment can beformed in seamless construction.

While embodiments have been described in which the floating (“bubble”)regions are arranged on an inner surface of a fabric garment, in someembodiments, the floating (“bubble”) regions may instead be arranged onan outer surface of a fabric garment, facing away from a wearer's skin,to provide an aesthetic look.

In some cases, the face yarn and/or the back yarn can include flameretardant fibers.

In some embodiments, the composite textile fabric may have sweatshirttype weight, and the yarn count can be 50 to 1000 denier on either orboth sides.

Other embodiments are within the scope of the following claims.

What is claimed is:
 1. A method of forming a composite fabric article,the method comprising: knitting a plaited construction composite textilefabric comprising a first fabric layer and a second fabric layer,wherein the first fabric layer and the second fabric layer are formedconcurrently, wherein the second layer comprises a plurality of anchoredregions and a plurality of floating regions, wherein the plurality offloating regions are interspersed between the anchored regions, whereinin the anchored regions the first fabric layer and the second fabriclayer are connected together, and wherein in the floating regions thefirst fabric layer and second fabric layer are unattached, wherein thefirst fabric layer is formed from a face yarn and the second fabriclayer is formed from a back yarn, wherein the face yarn has about 10-60%shrinkage after being exposed to dry or wet heat for about 0.5-60minutes at about 200-450° F., and wherein the back yarn has about 0-30%shrinkage after being exposed to dry or wet heat for about 0.5-60minutes at about 200-450° F.; and, exposing the composite textile fabricto wet heat for about 0.5-60 minutes at about 200-450° F., wherein theback yarn shrinks less than the face yarn causing the floating regionsof the second fabric layer to separate further from the first layer. 2.The method of claim 1, wherein the face yarn has a finer denier than theback yarn.
 3. The method of claim 1, wherein the face yarn has a sizerange of between about 50 to 150 denier and the back yarn has a sizerange of between about 50 to 300 denier.
 4. The method of claim 1,wherein in the anchored regions the back yarn of the second layer isanchored to the face yarn of the first layer using stitches selectedfrom the group consisting of knit, tuck, and welt.
 5. The method ofclaim 1, wherein the size of floating regions changes along the secondfabric layer.
 6. The method of claim 1, wherein a portion of thecomposite textile fabric comprises floating regions in the second fabriclayer and a portion of the composite textile fabric comprises a plainplaited construction with no floating regions.
 7. A method of forming acomposite fabric article, the method comprising: knitting a plaitedconstruction composite textile fabric comprising a first fabric layerand a second fabric layer, wherein the first fabric layer and the secondfabric layer are formed concurrently, wherein the second layer comprisesa plurality of anchored regions and a plurality of floating regions,wherein the plurality of floating regions are interspersed between theanchored regions, where in the anchored regions the first fabric layerand the second fabric layer are connected together, and wherein in thefloating regions the first fabric layer and second fabric layer areunattached, wherein the first fabric layer is formed from a face yarnand the second fabric layer is formed from a back yarn, wherein the faceyarn has about 10-60% shrinkage after being exposed to dry or wet heatfor about 0.5-60 minutes at about 200-450° F., and wherein the back yarnhas about 0-30% shrinkage after being exposed to dry or wet heat forabout 0.5-60 minutes at about 200-450° F.; exposing the compositetextile fabric to wet heat for about 0.5-60 minutes at about 200-450°F., wherein the back yarn shrinks less than the face yarn causing thefloating regions of the second fabric layer to separate further from thefirst layer; and, forming the composite textile fabric into a fabricgarment.
 8. The method of claim 7, wherein the composite textile fabricis oriented in the garment such that the second fabric layer ispositioned towards a wearer's skin.
 9. The method of claim 7, whereinthe size of floating regions changes along the second fabric layer. 10.The method of claim 7, wherein the size of floating regions changesalong the second fabric layer.
 11. The method of claim 7, wherein thefabric garment comprises a first area having a first bubbleconfiguration with a plurality of floating regions and a second areahaving a second bubble configuration with a plurality of floatingregions, wherein the first bubble configuration has a greater patterndensity of floating regions than the second bubble configuration. 12.The method of claim 7, wherein the fabric garment comprises a first areahaving a first bubble configuration with a plurality of floating regionsand a second area having a second bubble configuration with a pluralityof floating regions, wherein the floating regions in the first bubbleconfiguration are larger than the floating regions in the second bubbleconfiguration.
 13. The method of claim 7, wherein a portion of thecomposite textile fabric comprises floating regions in the second fabriclayer and a portion of the composite textile fabric comprises a plainplaited construction with no floating regions.
 14. The method of claim7, wherein a portion of the fabric garment comprises a composite textilefabric having floating regions in the second fabric layer and a portionof the fabric garment comprises a plain plaited construction with nofloating regions.